I had the strut TSB applied and the noise was still there. I went back to the dealer and they said that one of the motor mount under the engine attached to the transmission was faulty. I have just got my car back from the dealer and the noise seems gone. We'll see if it still gone in a few days but here's the part they have replaced. (Well, this is the part that is shown on the work order...)

Update: I had one of the motor mount replaced (CV6Z-6068-A) but the clunking noise is back. I went back to the dealer yesterday and now they say they can't start replacing all the engine mounts without knowing if it will fix the problem so I am back to square 1. I have been to the dealer about 10 times about this issue already so I am a bit frustrated. Here's how I can reproduce the problem; I am guessing if we share this info it would help.

1. It happens when the engine is either cold or hot.
2. I find a road with a very bad surface and a lot of short bumps. (Not hard to find with the crappy roads here in Canada LOL...)
3. I put the car in 1st or 2nd gear and do no exceed 30 KM/h. (I have a SE with the manual 5spd.)
4. Then I get a metal to metal clunking noise that is more than just annoying; I feel like my engine is hard mounted to the frame and that it's loose.

I really feel it's not a suspension issue. If you are still having this same issue; are you able to reproduce it at will or it just happen random?

Well I have mine in the shop today for the Tranny noise and the "clunking" noise. I am not too concerned as of yet with the tranny noise but the clanking noise which is repeatable by slowly driving over a speed bump "Clank,Clank" I am. I went on a drive with the shop foreman and he thinks it is front suspension related. I called back after a few hours to get the status and was told the lower control arm needed to be replaced and that the parts will have to be ordered.
I also went on a drive with the shop foreman in New same model Focus with 12 Miles on it and it is noticeably different like no clunk and Quiet.
I'll post back after the repair and inform on the results.

Bob

Here is my invoice for today looks like only the left strut needs to be replaced. Will see?

I can make the sound happen simply by kicking the tire pretty hard on the left front. The other side makes no noise. It always happens going very slow over small sharp bumps. Something is loose. I'm taking it in soon

Mine has the same clunk and it's only at lower speeds (below 15 mph) or while coming to a stop. I never hear it while accelerating or driving at a steady speed. Hopefully when I drop it off Thursday, they'll figure it out; and this time I'll request going on a test drive with a tech before I leave the car. Last time I had it in, I insisted it was the motor mounts and they said they checked and the mounts were fine. The more and more I hear it, the more I think it's suspension related.

Well I have mine in the shop today for the Tranny noise and the "clunking" noise. I am not too concerned as of yet with the tranny noise but the clanking noise which is repeatable by slowly driving over a speed bump "Clank,Clank" I am...

Hello bobakman,

Thank you for the information via PM and your patience while the service department works on the Focus. Keep me posted on the results.

Quote:

Originally Posted by Lipshurt

...It always happens going very slow over small sharp bumps. Something is loose. I'm taking it in soon

Hi Lipshurt,

Pleasure to meet you!

Shoot me a PM with the VIN, current mileage, personal and dealer contact and I'll escalate the concern to the Customer Service Manager for review.

Quote:

Originally Posted by jjeremyy

...Hopefully when I drop it off Thursday, they'll figure it out...

Hey jjeremyy,

What's the status on your Focus? If you like, we can add another layer of assistance from the Customer Service Manger. Send me a PM with the VIN, current mileage, personal and dealer contact to begin the process of escalation.

What's the status on your Focus? If you like, we can add another layer of assistance from the Customer Service Manger. Send me a PM with the VIN, current mileage, personal and dealer contact to begin the process of escalation.

Thanks all!

Noemi

Noemi - Thanks so much for the response. I'm going to give them another shot first and see what happens. I'll send you a PM if I need any help. Thanks again! :-)

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